Remove/install turbocharger

AR09.40-D-6020TSV

Remove/install turbocharger

06.03.2020

Engine

642 in model 907

1

Turbocharger

6

Electrical connector

10

Bracket

2

Rear exhaust gas recirculation line

7

Temperature sensor

11

Bolts

3

Exhaust collector pipe

8

Electrical connector

12

Bolts

4

Bracket

9

Boost pressure positioner

13

Bolts

5

Bracket

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 

Remove/install

1

Remove right holder for air filter housing at firewall.

AR09.10-D-1149TS

2

Remove ventilation box.

AR83.10-D-0010TS

3

Remove exhaust pipe downstream of the exhaust gas turbocharger (1).

AR49.10-D-5532TSV

4

Remove rear exhaust gas recirculation line (2) from exhaust gas collector pipe (3), exhaust gas recirculation, and the brackets (4).

AR14.20-D-1061TSV

 Rear exhaust gas recirculation line (2) cannot be removed.

5

Remove noise damper on exhaust gas turbocharger (1).

AR09.40-D-6920TSV

6

Unclip bracket (5).

7

Disconnect electrical connector (6) for temperature sensor (7).

8

Disconnect electrical connector (8) for boost pressure actuator (9).

9

Remove bracket (10).

 To do this, unscrew screws.

 Bolt, bracket for exhaust gas turbocharger to charge-air distributor

*BA09.40-N-1005-02TSV

10

Remove screws (11).

 Bolt, exhaust manifold to exhaust gas collector pipe

*BA14.10-N-1003-02TSV

11

Remove screws (12).

 Bolt, holder for exhaust gas collector pipe to exhaust gas collector pipe

*BA09.40-N-1006-02TSV

12

Unscrew screws (13).

 Bolt, exhaust gas turbocharger to oil supply connection fitting

*BA09.40-N-1003-02TSV

13

Remove exhaust gas turbocharger (1) upwards.

 Seal connections.

 Installation: Replace seals on exhaust manifolds and on oil supply connection fitting.

 Set of protective covers

*001589019100

 Record plug

*129589009100

If exhaust gas turbocharger (1) is replaced,



do not dispose of old seals from exhaust manifolds and from oil supply connection fitting yet.

14

Transfer temperature sensor (7).

If exhaust gas turbocharger (1) is replaced.

AR07.04-D-0244TSV

15

Replace seal between exhaust gas turbocharger (1) and exhaust gas collector pipe (3).

If exhaust gas turbocharger (1) is replaced.

AR09.40-D-6024-15TSV

 WIS Service Media
wsm://04_ 201900_45

 Screw/bolt, turbocharger to exhaust collector pipe

*BA09.40-N-1004-02TSV



Clean

16

Clean sealing surfaces on exhaust gas collector pipe (3), exhaust manifolds, and oil supply connection fitting.


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.

Assembly cleaner

*BR00.45-Z-1028-04A

17

Clean sealing surfaces on exhaust gas turbocharger (1).

If exhaust gas turbocharger (1) is reused.


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.

Assembly cleaner

*BR00.45-Z-1028-04A

18

Install in the reverse order.

 Turbocharger

Number

Designation

Engine 642 in model 907

BA09.40-N-1003-02TSV

Bolt, exhaust gas turbocharger to oil supply connection fitting

Stage 1

Nm

10

Stage 2

Nm

20

Stage 3

°

60

 Turbocharger

Number

Designation

Engine 642 in model 907

BA09.40-N-1004-02TSV

Screw/bolt, turbocharger to exhaust collector pipe

Stage 1

Nm

20

Stage 2

°

90

 Turbocharger

Number

Designation

Engine 642 in model 907

BA09.40-N-1005-02TSV

Bolt, bracket for exhaust gas turbocharger to charge-air distributor

Nm

10

 Turbocharger

Number

Designation

Engine 642 in model 907

BA09.40-N-1006-02TSV

Bolt, holder for exhaust gas collector pipe to exhaust gas collector pipe

Nm

30

 Exhaust manifold

Number

Designation

Engine 642 in model 907

BA14.10-N-1003-02TSV

Bolt, exhaust manifold to exhaust gas collector pipe

Stage 1

Nm

20

Stage 2

°

90

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01